Research Assignment

HSE CBB 2012

January 2011

Executive Summary
Heat risks are well-known to be one of those common factors leading to disruption and accidents in workplace especially in metal-based industries. This industries conducting numbers of operations which involve high temperature and direct physical contact with hot objects as well as exposed to radiant heat source which may expose workers to hazards. In this study, a moderate research is conducted upon the cases on heat risk in steel production industries. The study includes introduction towards heat risks in steel production industries and the causes and factors that lead to the hazards. Apart from that, study cases on heat risks both in local and foreign industries are also compiled along the research materials to provide good enhancement and comprehension on real problem situations. At the end of the research, list of preventive measures on heat risk is inserted to comply with research title; Reduction of Heat Risks in Steel Production Industries. The research are conducted within quantitative and qualitative information provided in internet consisting of academic journals as wells as interview of reliable party on the issue. As follows are the objectives of the study: Objective of research: 1. To study basic information of heat risk including definitions, history as well as HSE organizations views on heat risk. 2. To find the factors and causes that lead to heat risk in steel production industries. 3. To view the study cases on heat risks in steel production industries both local and foreign. 4. To enlist the preventive measures on heat risk hazards as agreed by related authorized organization.

Research Assignment

HSE CBB 2012

January 2011

Chapter 1 Heat Risk : Introduction

As according to Oxford Advanced Learners Dictionary International Student Edition (7th Edition), heat risk can be defined as the possibility of something happening at some time in future related to heat. From Health Safety and Environment (HSE) perspective, heat risk can be defined as combination of likelihood of heat hazard and the severity of the consequences. Mass production of steel had begun in 1856 following the introduction of the Bessemer process, by reducing the carbon content in the molten pig iron. This has become basis for steel production in the modern world. The introduction of the process by Sir Henry Bessemer (1813-1898), led to a revolution in steel industry in which it up until 1884; 1,500,000 tons of steel had been produced. Later many processes are introduced to the industry such as open-hearth process by German engineer Karl Wilhelm Siemens. However steel industry involves risks to workers and can possibly lead to injuries and fatality. Steel industry involves physical, chemical and radiation hazards to the workers. Physical hazards such as unguarded machinery, moving machinery, fire and explosion, extreme temperatures, contact with molten metal, etc. Chemical hazards such as inhaling poisonous gasses, skin contact with chemicals; this is due to steel industry involves chemical reaction to modify an iron ore into steel. Meanwhile, radiation hazards are due to ionizing phase of steel production process. These hazards lead to accidents. As an example; one explosion happened and causing fatality to workers at Port Talbot's Corus steelworks. Thus, many Health, Safety, and Environment (HSE) regulation has been applied to this industry. One of organization that handles with HSE regulation in steel making industry is International Labour Organization (ILO). In 2005 ILO has discussed codes of practice in iron and steel industry to ensure the safety of every component involves in steel making industry. This action is taken to prevent and minimize the risk, and to avoid industry to repeat the same mistake happened in the past.

Research Assignment

HSE CBB 2012

January 2011

Chapter 2 Heat Risk : Sources and Factors

The presence of heat risk in any metal industry would definitely be expected. However, in order to minimize the risk, causes that lead to the risks need to be identified. This is to ensure that proper precautions could be taken in order to prevent any incidents or accidents from occurring. Among the causes are fire, explosion, and machinery breakdown. Fire The use of fire in any metal industry is a must. Fire is used to change the properties of metal to allow them to be shape. In other cases, fire is also a product of metal processes such as milling and drilling. In an event when fire occurs in a milling machine, the biggest concern is not the mill, but rather the motor, electrical cable trays, electrical tunnel which are contain higher. As a motor of the machine in any case caught fire, would definitely result in the disaster not only producing a risk to the person operating the machine, but could cause a long Business Interruption period to the company. Fire could also occur anywhere in a metal industry such as due to short-circuits, smoking in restricted area and due to molten metal spill. Explosion Explosions are mostly to occur in oxygen generating plants, coke ovens and steam generators. Without proper handling of these facilities, an explosion is a great risk that could result in a terrible disaster. An accident happened in Pittsburgh, US, where a coke oven exploded resulting in injuries to 20 workers. The accident that happened at United States Steel Corp.'s Clairton Coke was said to have been caused by the gas used to heat one of the coke ovens. The risk for an explosion to happen are also dependant on a few factors such as mixing of chemicals, heating chemicals, also indirect heat such as smoking and poor ventilation. Machinery Breakdown In any metal industry, machines are used for higher production and more accurate results. As machines are used, they contain a potential to lead towards a heat risk. Machines are made to help us increase productions. However, as humans have the tendency to get tired and fatigue, machines also have their limit.

Research Assignment

HSE CBB 2012

January 2011

Machines need to be properly examined and maintained in order for it to function properly. In cases like discussed before, the process of milling for example could lead to a fire. In a case where a machine is not properly maintained, it would easily contribute towards an accident as the machine would be exposed to catching the fire.

Research Assignment

HSE CBB 2012

January 2011

Chapter 3 Heat Risk : Cases and Accidents

'Hero' steelworker in fatal fall
A father-of-two who helped rescue injured workers in the 2001 explosion at Port Talbot's Corus steelworks has died after falling into molten waste. Kevin Downey, 49, from Port Talbot, was treated at Swansea's Morriston Hospital after the accident at 0415 BST on Tuesday. Referring to his involvement in the 2001 tragedy when three men died, Corus said he was Two separate investigations instrumental in helping. Colleagues and the local press had into the accident are under dubbed him a "hero" for his actions. Mr Downey, who began way working at the plant when he left school, was said to have been pivotal in shutting the furnace down after the explosion five years ago and making the area safe. The blast - which was the worst accident in the UK steel industry for 27 years - killed Stephen Galsworthy, who was 25, Andrew Hutin, 20, and Len Radford, 53. Married with a daughter and a son who also worked at the plant, it appears Mr Downey fell into a piece of equipment known as a "slag runner" while working in blast furnace number four. He suffered massive burns. Corus said the accident had "created an unbelievable amount of shock and grief". The 2001 blast was the worst steel industry accident A company spokesman said there was no explosion, in 27 years venting of gas or any other obvious catastrophic failure before the accident. Protective clothing and other systems were also said to have been working. http://news.bbc.co.uk/2/hi/uk_news/wales/4946330.stm

Research Assignment

HSE CBB 2012

January 2011

Major accident in Vizag Steel plant.

A major accident occurred in the prestigious Navratna starred Vizag Steel Plant, Visakhapatnam on Sunday morning. While, transferring the hot molten steel at steel melting shop-2, it leaks out from the ladle and damaged the electrical cables and other equipment worth Rs. 100crore. About, 120 tons of hot molten steel spilled across the floors in the melting shop. Fortunately, all the 8 workers who were working around have narrowly escaped a fatal incident by running away from the place.

According to reports, it happened due to damaged brick lining of the ladle. Usually, the ladles are used to transfer the hot molten metal in liquid form to CCD where it will be molded in to ingots. Hence, the brick lining provided inside the ladle has to withstand 1700degrees heat of the molten metal. This brick lining of the ladles is to be changed after every 6500 heats. But, according to reports the management has preferred to use the ladle without periodical change, which causes Rs.100 crore loss to the plant. It will take a minimum3 months time to revive the activities in that particular section. The loss of production during this period further escalates the loss. It is estimated that, a minimum production loss would be around 1000tons per day.

http://www.bharatwaves.com/news/Major-accident-in-Vizag-Steel-plant-18468.html

Molten steel kills 32 Chinese workers

At least 32 workers were killed and two injured today when they were buried in whitehot molten steel at a metal factory in North East China, officials said. The mishap was triggered when a 30-tonne-capacity steel ladle sheared off from the blast furnace, spilling liquid metal onto the factory floor three metres below. The molten steel engulfed an adjacent room where workers had gathered for a routine shift change, the State Work Safety Administration said. Rescuers were unable to get closer because of the intense heat emitted from the white-hot liquid metal which rose to 1,500 C (2,732 F), according to the state-run Xinhua news agency. The accident at Qinghe Special Steel Corp in Liaoning province highlights Chinas dismal industrial safety record, and came as the government prepared to announce yet

Research Assignment

HSE CBB 2012

January 2011

another double-digit expansion of the nations booming economy in the first quarter of 2007. It happened at about 7:45 am local time in a factory workship located in Tieling, a city of about three million people in Chinas industrial heartland. An official at the Qinghe crematorium in Tieling told AFP by phone that families of victims had gathered to view their loved ones, but police were refusing to allow them in until the bodies were identified. They are going to have to identify the bodies through DNA testing because the victims were burnt beyond recognition, the official said. It was unclear how many people were working at the time of the accident, or whether the workers in the room were ending or beginning their shifts. Two machine operators were also injured. http://www.timesonline.co.uk/tol/news/world/article1671455.ece

Diagram on effects of heat risk hazard

SOME EXAMPLE OF CASES IN MALAYSIA: pounds of molten metal;

Case Title Location Date Summary of Accident : : : : Workers died of burns throughout the body Factories, in Johor 16-03-2008 A foreign worker died from burns throughout the body when it finished its repairs and change of 4 units 75Amp Low Voltage Board. Suddenly an explosion occurred and the victim had suffered from fire and burns the entire body. The victim was taken to hospital and died several days later. Suddenly an explosion occurred when the victim completes the work. No safe work procedures Burns

Contributing Factors Fine Classification of Accident

: : :

Research Assignment

HSE CBB 2012

January 2011

Case Title Case Title Place Location Date Date Summary of Accident

: : : :

Explosion during repair works machinery Sulawesi Killed the repair work Plantation, Setiu, Terengganu Plantation, Setiu, Terengganu 25-01-2010 Robiul, 30 years, citizens of Bangladesh, died after being burned throughout the body when the reactor is under repair (welding) and then grabbed the victim explodes. To Killed After Boiler Exploded Factory, Sabah 04-12-2009 Two (2) factory workers were killed when a boiler exploded. Before the incident, both workers were instructed to operate the fire tube boiler to supply steam to the operation area while waiting for rectification (blocked fuel feeder) works to the main boiler completed. After the rectification works to the main boiler were completed and the steam pressure was back to operating pressure, the workers were again instructed to stop the operation of the fire tube boiler. During the process of stopping the boiler operation, it exploded causing both the decease to die at the spot, struck by flying fragments from the boiler and superheated water. Both the victims were not competent persons Lack of safe work procedures Explosion

Case Title Location Date Summary of Accident

: : : :

Contributing Factors Fine Classification of Accident

: : :

http://www.dosh.gov.my/doshv2/includes/statistic/main.php?s=20&np=2

Research Assignment

HSE CBB 2012

January 2011

Chapter 4 Heat Risk : Preventive Measures

Most processes in the steel production company are dealing with heat. Heat, on the other hand could give many hazards to human that working in the company. There are many hazards that will be occurred if there are no any policies or regulations and also prevention steps taken. Hazards in heat treatment include burns and scalding, mechanical hazards from steel handling, and hazards arising from the annealing gases, including nitrogen, hydrogen and carbon monoxide. Furnace insulation wools can expose workers to hazardous fibers. Thus, a company should have prevention steps taken and regulations that workers or employees must obey. These are the list we can get from one company in America.

The Preventive Measure taken:

We can divide the preventive measure into three (3) aspects: 1.0. Workers exposed to heat or cold, as well as their supervisors, should be trained: 1.1. To recognize symptoms which may lead to heat stress or hypothermia, in themselves or others, and the steps to be taken to prevent onset and / or emergencies? 1.2. In the use of rescue and first-aid measures; and 1.3. In action to be taken in the event of increased risks of accidents because of high or low temperatures. 2.1. Employers should make the necessary arrangements to provide for: 2.1.1. Regular surveillance of the working environment, and health surveillance; 2.1.2. Adequate and competent supervision of work and work practices; 2.1.3. The application and use of appropriate control measures and the periodic review of their effectiveness; 2.1.4. Education and training to managers, supervisors and workers, and to workers safety and health representatives, on issues relating to hazards in the production of iron and steel; and 2.1.5. Where necessary, measures to deal with emergencies and accidents, including first-aid arrangements.

Research Assignment

HSE CBB 2012

January 2011

2.2.

Employers should verify: 2.2.1. Compliance with safety regulations; 2.2.2. Maintenance of safe working techniques; 2.2.3. The care taken of machines and equipment, particularly any devices provided in the interest of safety; 2.2.4. Training in the use of and the care taken of personal protective equipment (PPE); and 2.2.5. The competence of managers, supervisors and workers for their tasks.

3.0.

Workplace heat hazard control: 3.1. The work area and the flow of material through it should be designed so as to minimize the possibility of worker contact with hot steel, or to scalding in the case of quenching operations. 3.2. Inert annealing gases should be handled in a way that prevents their buildup in enclosed spaces other than the furnace itself, so as to prevent asphyxiation. Annealing furnaces should be considered to be hazardous confined spaces. 3.3. The system for handling flammable annealing gases like hydrogen should minimize the possibility of an explosive build-up. 3.4. Carbon monoxide should not be used for carburizing (a process for adding carbon to the surface) where safer processes are practicable. 3.5. The safest practicable furnace insulation should be used. In general, this means using insulation wools with a low content of respirable fibers, and which do not convert to silica when heated. Compressed air should never be used to clear away residual insulation wool gasketing used around box annealing furnaces. 3.6. Forklift trucks used to transport molten material should have solid tyres and their fuel tanks should be protected and insulated from ignition. The drivers station should have rigid splashguards fitted. 3.7. Lifting devices should be made of steel that is not prone to hydrogen embrittlement and should be shielded from radiant heat. 3.8. Workstations should not be located underneath the path of molten material. 3.9. Appropriate PPE, such as helmets, gloves, aprons and boots should be provided and used. Where appropriate, molten metal resistant clothing should be provided and used.
(Safety and health in the iron and steel industry,Second edition,
International Labour Office, Geneva)

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Research Assignment

HSE CBB 2012

January 2011

Chapter 5 Heat Risk : Conclusion

As a conclusion, studies has proven that heat risks as one of the major hazard problems frequently occur in workplace specifically in steel production industries that may lead to major disaster if least preventive steps are taken. Thus, monitoring the probability of factors that may tend to cause heat hazards must be at the maximum efforts to prevent accidents related to heat risks. Those factors must be controlled efficiently as minor mistakes will result in huge impacts, from slight burning effect up to fatality. Study cases provided has shown that most of accidents related to heat risk hazard came from human errors and carelessness mistakes. While prevention is better than cure, thus early stage of process to reduce and prevent heat risk must be filled with human development programs such as training for workers. This will help to place heat risk hazard potential at the lowest level due to adequate knowledge attained by workers before they are provided with heavy task on heat-related operations in industries. Last but not least, reduction of heat risk in steel production industries must be comprehended very well due to its vital importance to the production of a company. Damage made by heat risk hazard may result in huge loss both financially and lives of the workers including the professional experts. As result, production will decrease dramatically and will affect the supply of respective products to consumers.

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Research Assignment

HSE CBB 2012

January 2011

Bibliography
Reference:
1. http://ehs.unc.edu/ih/docs/heat_stress_sugg.pdf 2. http://www.ilo.org/public/english/dialogue/sector/techmeet/meisi05/code.pdf 3. http://books.google.com.my/books?id=nDhpLa1rl44C&pg=PT883&lpg=PT883&dq=preventive+ measure+to+reduce+heat+risk+in+steel+company&source=bl&ots=zLRkOPHzjT&sig=k0QLzRnO_9fZ33V1fNOmhcg6w&hl=en&ei=gHyqTY__DonsrAfA9ZmoCA&sa=X&oi=book_result&ct=result&resnum=1&ved=0C BcQ6AEwAA#v=onepage&q&f=false 4. http://www.compwestinsurance.com/documents/LC_Guide%20Heat%20Illness%20Sample%20 Program%20.pdf 5. http://www.tdi.state.tx.us/pubs/videoresource/stpheatst.pdf 6. http://www.ehow.com/list_7410022_safety-issues-explosions-lab.html 7. http://www.dispatch.com/live/content/national_world/stories/2010/07/15/u-s-steel-cokeoven-explosion-near-pittsburgh-injures-20.html 8. http://www.ehow.com/list_7410022_safety-issues-explosions-lab.html 9. http://www.dispatch.com/live/content/national_world/stories/2010/07/15/u-s-steel-cokeoven-explosion-near-pittsburgh-injures-20.html 10. http://news.bbc.co.uk/2/hi/uk_news/wales/4946330.stm 11. http://www.bharatwaves.com/news/Major-accident-in-Vizag-Steel-plant-18468.html 12. http://www.timesonline.co.uk/tol/news/world/article1671455.ece 13. http://www.columbusworkerscompensationblog.com/2011/02/furnace-failure-spills-9000pounds-of-molten-metal-workers-sue.shtml 14. http://dergi.omu.edu.tr/index.php/JECM/article/download/801/1247 15. http://www.dosh.gov.my/doshv2/includes/statistic/main.php?s=20&np=2 16. http://www.anselm.edu/homepage/dbanach/h-carnegie-steel.htm

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Research Assignment

HSE CBB 2012

January 2011

Appendixes
Developed through an extensive process of consultation with leading professionals and health and safety institutions worldwide, the new, expanded, and long-awaited Fourth Edition of this well-respected reference provides comprehensive, timely, and accurate coverage of occupational health and safety. Aimed at the specialist and nonspecialist alike, such as lawyers, doctors, nurses, engineers, toxicologists, regulators, and other safety professionals, this compendium is organized and designed to provide the most critical information in an easy-to-read format.

Key Features * Provides practical guidelines for industrial compliance with major OSHA regulations * Presents concise explanations of technical and scientific concepts underlying regulatory requirements * Integrates specific examples of the global economy's influence on the design and implementation of workplace health and safety * Elucidates the effects of health and safety programs on financial and legal risk management practices in industry * Includes explanations of practical alternative compliance strategies for company health and safety officers

*condition in steel production companies*

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